INSTALLATION INSTRUCTIONS R-410A Duct Free Split System Air

INSTALLATION INSTRUCTIONS
R-410A Duct Free Split System
Air Conditioner and Heat Pump
Product Family: DFC4(A/H)3, DFF4(A/H)H
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . 2-3
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE VALVE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INDOOR UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . 5-7
Install Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
NOTE: Read the entire instruction manual before starting
the installation.
Drill Hole in Wall for Connecting Piping,Drain&Wiring.. 5
Piping and Drainage Connections . . . . . . . . . . . . . . . . . 6
Install Indoor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connect Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remote Control Installation . . . . . . . . . . . . . . . . . . . . . . 6
Control and Power Wiring from Outdoor Unit . . . . . . . 7
OUTDOOR UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . 8-9
Installation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Make Refrigerant Piping Connections . . . . . . . . . . . . . 8
Wiring Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . 10
SYSTEM VACUUM AND CHARGE . . . . . . . . . . . . . . . 11-12
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
421 01 9300 00 Sep 2007
INSTALLATION INSTRUCTIONS
R-410A Duct Free Split System: DFC4(A/H)3, DFF4(A/H)H
SAFETY CONSIDERATIONS
Installing, starting up, and servicing air-conditioning
equipment can be hazardous due to system pressures,
electrical components, and equipment location (roofs,
elevated structures, etc.).
Only trained, qualified installers and service mechanics
should install, start-up, and service this equipment.
Untrained personnel can perform basic maintenance
functions such as cleaning coils. All other operations should
be performed by trained service personnel.
When working on the equipment, observe precautions in the
literature and on tags, stickers, and labels attached to the
equipment.
Follow all safety codes. Wear safety glasses and work
gloves. Keep quenching cloth and fire extinguisher nearby
when brazing. Use care in handling, rigging, and setting
bulky equipment.
Read these instructions thoroughly and follow all warnings
or cautions included in literature and attached to the unit.
Consult local building codes and National Electrical Code
(NEC) for special requirements.
Recognize safety
information. This is the safety-alert symbol !! . When you
see this symbol on the unit and in instructions or manuals,
be alert to the potential for personal injury.Understand these
signal words: DANGER, WARNING, and CAUTION. These
words are used with the safety-alert symbol. DANGER
identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies
hazards which could result in personal injury or death.
CAUTION is used to identify unsafe practices which may
result in minor personal injury or product and property
damage. NOTE is used to highlight suggestions which will
result in enhanced installation, reliability, or operation.
WARNING
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in
personal injury or death.
Before installing, modifying, or servicing system,
main electrical disconnect switch must be in the
OFF position. There may be more than 1
disconnect switch. Lock out and tag switch with a
suitable warning label.
!
CAUTION
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Do not bury more than 36 in. (914 mm) of refrigerant
pipe in the ground. If any section of pipe is buried, there
must be a 6 in. (152 mm) vertical rise to the valve
connections on the outdoor units. If more than the
recommended length is buried, refrigerant may migrate
to the cooler buried section during extended periods of
system shutdown. This causes refrigerant slugging and
could possibly damage the compressor at start-up.
GENERAL
These instructions cover the installation, start-up and
servicing of DFC4(A/H)3 outdoor and DFF4(A/H)H indoor
units duct free systems.
SYSTEM REQUIREMENTS
IMPORTANT: Each refrigerant line must be insulated
separately.
IMPORTANT: Use refrigeration grade tubing ONLY. No
other type of tubing may be used. Use of other types of
tubing will void manufacturer's warranty.
Piping
Minimum refrigerant line length between the indoor and
outdoor units is 10 ft. (3 m).
The following maximum dimensions are allowed:
Unit Size
9K
12K
18K
24K
Refrigerant Charge
The outdoor unit is factory charged.
Unit Size
REFRIGERANT CHARGE lb. (kg)
Air Conditioner
9K
12K
18K
24K
2.3 (1.0)
2.9 (1.3)
4.4 (2.0)
TBD
Heat Pump
2.4 (1.1)
3.0 (1.4)
TBD
TBD
REFRIGERANT LINE LENGTHS ft. (m)
Max Elevation
Max Elevation
Max Line Length
(ID over OD)
(OD over ID)
65 (20)
65 (20)
100 (30)
100 (30)
35 (11)
35 (11)
50 (15)
60 (18)
35 (11)
35 (11)
50 (15)
60 (18)
The following are the piping sizes.
Unit Size
9K
12K
18K
24K
2
PIPE SIZES
Mix Phase
1/4”
1/4”
1/4”
3/8”
Vapor
3/8”
1/2”
1/2”
5/8”
421 02 9300 00
INSTALLATION INSTRUCTIONS
R-410A Duct Free Split System: DFC4(A/H)3, DFF4(A/H)H
Power Wiring
Consult local building codes, NEC (National Electrical
Code) or CEC (Canadian Electrical Code) for special
requirements.
Connecting Cable: Voltage drop on the connecting cable
should be kept to a minimum. Use cable size and max
length below:
#18 AWG
#16 AWG
50 Feet (16 m)
100 Feet (33 m)
Allow sufficient space for airflow and servicing unit. See
Fig. 1 and 2 for minimum required distances between unit
and walls or ceilings.
Do not install indoor units near a direct source of heat
such as direct sunlight or a heating appliance.
Model
Size
AWG (min.)
Connecting
Cable**
MIN CKT AMP
MAX FUSE/CB
AMP
Power Source
(outdoor to indoor)
9k
12/20
115-1-60
12k
18
15/25
12k
9/15
18k
18
11/20
208/230-1-60
18
24k
14/25
** Four conductor cable to comply with NEC and local codes.
PARTS LIST
Part
No.
1
2
3
4
5
6
Name of Part
Part
No.
1
2
3
4
5
6
Qty
Mounting Plate
Mounting Screw ST3.9x25-C-H
Anchor
Remote Control
Remote Control Holder
Mounting Screw B ST2.0x10-C-H
1
8
8
1
1
2
Name of Part
Mounting Plate
Mounting Screw A ST3.9x25-C-H
Anchor
Remote Control
Remote Control Holder
Mounting Screw B ST2.0x10-C-H
2
3
5" (1
5.0
" (1
3 cm
6.0" (15 cm) min. from ceiling
3c
m)
.
1
8
8
1
1
2
3
6" (
15
cm)
min
. fro
mc
) min
.
1
min
Qty
eilin
2
1
3
g
5" (1
3 cm
6' (1.8 m) min. from floor
) min
.
5.0
" (1
3c
6' (1.8 m) min. from floor
m)
Air
min
.
filte
r
4
Air
Remote Control
filte
r
Mounting screw B
ST2.9X10-C-H
12" (3
Remote control bracket
A
24" (60 cm)
or more
Air Inlet
4" (
1
or m 0 cm)
ore
) min
.
.
) min
30 cm
12" (
Air Inlet
)
cm
(30
12" more
or
Air outlet
24"
(6
or m 0 cm )
ore
.
) min
91 cm
36" (
)
cm
(60
24" more
or
B
0 cm
A
5
24" (60 cm) min.
Remote control bracket
6
4
Remote control
6
5
24" (6
0
B
cm) m
in.
C
C
Loop the
connecting
cable.
Loop the connecting
cable.
Remove the water receiver first
before connecting the pipes.
A07334
Fig. 1 - DFC4(A/H)3, DFF4(A/H)H 09-12
Parts List and Clearances
A07335
Fig. 2 - DFC4(A/H)3, DFF4(A/H)H
Parts List and Clearances
Note:
- If the outdoor unit is higher than the indoor unit, prevent rain from flowing into the indoor unit along the connection pipe by making a downward arc in the
connection pipe before it enters the wall to the indoor unit. This will ensure that rain will drip from the connection pipe before it enters the wall.
- The illustration above is only a sketch. Different models may be slightly different.
42101930000
3
INSTALLATION INSTRUCTIONS
R-410A Duct Free Split System: DFC4(A/H)3, DFF4(A/H)H
DIMENSIONS
INDOOR
W
in. (mm)
32.09 (815)
35.67 (906)
49.21 (1250)
49.21 (1250)
Model Size
9K
12K
18K
24K
H
in. (mm)
11.02 (280)
11.26 (286)
12.80 (325)
12.80 (325)
D
in. (mm)
7.68 (195)
9.25 (235)
9.06 (230)
9.06 (230)
Weight lb (kg)
24.2
33.0
55.0
55.0
(11)
(15)
(25)
(25)
OUTDOOR
H
Air Flow
W
L2
D
L1
35
W
in. (mm)
30.71 (780)
29.92 (760)
33.07 (840)
31.16 (893)
Model Size
9K
12K
18K
24K
H
in. (mm)
21.26 (540)
23.23 (590)
27.36 (695)
33.86 (860)
D
in. (mm)
10.87 (276)
11.42 (290)
13.19 (335)
13.11 (333)
L1
in. (mm)
21.61 (549)
20.87 (530)
22.05 (560)
23.11 (588)
L2
in. (mm)
11.81 (300)
12.40 (315)
14.17 (360)
13.98 (355)
Weight lb (kg)
Cooling Only
Weight lb (kg)
Heat Pumps
77.0 (35)
85.8 (39)
125.4 (57)
159.5 (72)
79.2 (36)
90.2 (41)
125.4 (57)
160.6 (73)
SERVICE VALVE LOCATIONS
24K
18K
12K
9K
K
J
Service Valve Locations
J
K
4
K
9K
in. (mm)
3.46 (88)
3.46 (88)
J
J
K
K
J
12K
in. (mm)
3.19 (81)
5.63 (143)
18K
in. (mm)
3.46 (88)
3.62 (92)
24K
in. (mm)
4.02 (102)
6.57 (167)
42101930000
INSTALLATION INSTRUCTIONS
R-410A Duct Free Split System: DFC4(A/H)3, DFF4(A/H)H
INSTALLATION TIPS
Ideal installation locations include:
Indoor Unit
A location where there are no obstacles near inlet and
outlet area.
A location which can bear the weight of indoor unit.
A location which provides appropriate clearances as
outlined in Fig. 1 and Fig. 2 (pg. 3).
Outdoor Unit
A location which is convenient to installation and not
exposed to strong wind. If unit is exposed to strong winds
it is recommended that a wind baffle be used. Contact
your representative for drawings.
A location which can bear the weight of outdoor unit and
where the outdoor unit can be mounted in a level position.
A location which provides appropriate clearances as
outlined in Fig. 1 and Fig. 2 (pg. 3).
Do not install the indoor or outdoor units in a location with
special environmental conditions. For those applications,
contact your representative.
INDOOR UNIT INSTALLATION
INSTALL MOUNTING PLATE
The mounting plate will look like one of the following
depending on model size:
6"(152) min. to ceiling
Mounting Plate
Indoor unit outline
Left rear side
refrigerant
pipe hole o 65
5.20"
(132)
3.19" (81)
11.10" (282"
4.72" (120)
or more to wall
23.50"(597)
4.72" (120) or more
to wall
3.54"
(90)
1.77"(45)
Right rear side
refrigerant
pipe hole o 65
32.09" (815)
1.77"
(45)
1.77"
(45)
NOTE: Measurements in ( ) are in mm.
6'(1.8 m) min. to floor
A07338
Fig. 3 - Mounting Plate- Model size 09
1.57" (40)
Indoor unit outline
6" (152) min.
to ceiling
Mounting Plate
2.05" (52)
32.01" (813)
11.26" (286)
4.72" (120)
or more to wall
4.72" (120)
or more to wall
1. Carefully remove the mounting plate, which is at‐
tached to the back of the indoor unit.
2. The mounting plate should be located horizontally
and level on the wall. All minimum spacings shown in
Fig. 3, 4, and 5 should be maintained.
3. If the wall is block, brick, concrete or similar material,
drill .2” (5 mm) diameter holes and insert anchors for
the appropriate mounting screws.
4. Attach the mounting plate to the wall.
DRILL HOLE IN WALL FOR INTERCONNECTING PIPING,
DRAIN AND WIRING
Refrigerant Line Routing
The refrigerant lines may be routed in any of the four
directions shown in Fig. 7.
If piping is going through the back:
1. Determine pipe hole position using the mounting plate
as a template. Drill pipe hole diameter per chart below.
The outside pipe hole is 2-in. (13 mm) min. lower than
inside pipe hole, so it slants slightly downward.
1/2 in. (13 mm)
Min.
1.99" (50)
1.99" (50)
Rear-left pipe
hole o 65mm
Rear-left pipe
hole o 65mm
35.63" (905)
3.86" (98)
2.17" (55) 5.00" (127)
3.54" (90)
6' (1.8 m) min.
to floor
A07339
Fig. 4 - Mounting Plate- Model size 12
INDOOR
OUTDOOR
Fig. 6 - Drill Holes
6" (152) min. from ceiling
Hooked Part
Above 4.72" (120)
from the wall
32.09" (815)
10.12" (257)
95
95
09, 12
18, 24
Mounting Plate
12.80" (325)
7.01"
(178)
Above 4.72" (120)
from the wall
2.17" (55)
Pipe hole
Indoor unit outline
2.28" (58)
Hole Diameter
in. (mm)
2.75 (70)
3.75 (95)
Model Size
Hooked Part
49.21" (1250)
Pipe hole
2.17" (55)
If piping is going through the right or left side:
1. Use a small saw blade to carefully remove the correspond‐
ing plastic covering on side panel and drill the appropriate
size hole where the pipe is going through the wall.
2.17" (55)
6' (1.8 m) min. to floor
Pipe holder
Pipe cover
A07340
4
Fig. 5 - Mounting Plate- Model sizes 18 - 24
Pipe cover
3
1
2
Left piping
Left back piping
Right back piping
Right piping
Size 012
Only
Fig. 7 - Piping Locations
42101930000
5
INSTALLATION INSTRUCTIONS
R-410A Duct Free Split System: DFC4(A/H)3, DFF4(A/H)H
PIPING AND DRAINAGE CONNECTIONS
NOTE: Before making any connections, remove the
front cover on unit size 12 only. This is not required on
unit sizes 09, 18, and 24.
Make Connections
1. Orient the refrigerant lines on the fan coils to match
the connection points.
2. Put upper claw at back of indoor unit on upper hook
of Mounting Plate, move indoor unit from side to side
to see that it is securely hooked. See Fig. 11.
3. Run electrical cable, refrigerant lines and drain line
through hole in the wall. All lines must be protected
where they pass through the wall.
4. Piping can be connected by lifting indoor unit with a
cushioning material between indoor unit and wall.
See Fig. 10.
5. Connect the refrigerant lines using a flare connection.
See System Requirements section for proper size.
Both lines must be separately insulated.
6. Connect the drain line. The drain line must not have
a trap anywhere in its length, must pitch downwards,
and must be insulated up to the outside wall. See Fig.
8.
Do not put the drain
end into water.
Do not form a rise.
A07342
Fig. 8 - Proper Drain Hose Installation
NOTE: For proper orientation of the refrigerant piping,
electrical cable, and drain lines, refer to Fig. 9
Indoor unit
INSTALL INDOOR UNIT
1. Be sure to remove cushioning after making all correc‐
tions.
2. Push lower part of indoor unit up on wall, then move
indoor unit from side to side, up and down to check if
it is hooked securely.
Upper hook
Cushioning material
Lower hook
A07347
Fig. 10 - Indoor Unit Installation
CONNECT FIELD WIRING
NOTE: A disconnect should be provided per NEC and local
codes.
For Sizes 09, 18, 24
1. Lift the panel, loosen the screws, and remove the
control box cover.
2. Connect wires to the terminal block per the connec‐
tion diagrams (Fig. 16, p.10) corresponding to the
correct unit capacity and voltage.
3. Cover the control box and close the front panel.
For Size 12
The front cover should have been removed.
1. Loosen the screws and remove the control box cover.
2. Connect wires to the terminal block per the connec‐
tion diagrams (Fig. 16, p.10) corresponding to the
correct unit capacity and voltage.
3. Cover the control box and install the front cover.
REMOTE CONTROL INSTALLATION
Interconnecting
Wiring
.. . . . .
.. . . . .
. . . .. .
..
..
.
. ... .. . .
.
Refrigerant Piping
Tape
Drain Piping
A07346
Fig. 9 - Proper Orientation
6
NOTE: For applications where gravity cannot be used for
drainage, a condensate pump accessory is available.
Consult the condensate pump Installation Instructions for
more information.
Mounting Bracket (if installed on the wall)
1. Use the two screws supplied with control to attach
Mounting Bracket to wall in location selected by cus‐
tomer and within operating range.
2. Install batteries in Remote Control.
3. Place Remote Control into remote control Mounting
Bracket.
4. For remote control operation, refer to the unit Owner's
Manual.
42101930000
INSTALLATION INSTRUCTIONS
R-410A Duct Free Split System: DFC4(A/H)3, DFF4(A/H)H
CONTROL AND POWER WIRING FROM OUTDOOR UNIT
Frame
Screw Cover
Frame
Panel
Panel
Window Cover
Screw
Control and Power Wire
18 AWG Min.
3/8"
(10 mm)
2"
(51 mm)
Terminal block of indoor unit
1
2
3
4
12v DC from outdoor
to board
35v DC from
outdoor to indoor
To Outdoor Unit
A07348
Fig. 11 - Control and Power Wiring - model size 9k - 12k
Panel
Control Box Cover
Terminal block
L1 L2
208/230-1-60
From outdoor unit
to indoor unit
S
G
24v DC
From outdoor unit
to indoor unit
Barrier between
high and low voltage
Control and Power Wire
18 AWG Min.
3/8"
(10 mm)
To outdoor unit
2"
(51 mm)
Terminal block of indoor unit
A07349
Fig. 12 - Control and Power Wiring - model size 18k-24k
42101930000
7
INSTALLATION INSTRUCTIONS
R-410A Duct Free Split System: DFC4(A/H)3, DFF4(A/H)H
OUTDOOR UNIT INSTALLATION
INSTALLATION TIPS
Install the outdoor unit on a rigid base to support unit in a
level position.
Make sure that the discharge air is not blocked.
For applications requiring cooling with outdoor
temperatures below 55F (13C), a low ambient control is
available. Consult the Installation Instruction for the low
ambient kit for further information.
If the installation location may be exposed to strong wind ,
use a wind baffle. See Fig. 13. Check with your
representative to obtain drawings for wind baffles.
Strong
wind
A07350
Fig. 13 - High Wind Installation
MAKE REFRIGERANT PIPING CONNECTIONS
(OUTDOOR UNIT)
IMPORTANT: Use refrigeration grade tubing ONLY. No
other type of tubing may be used. Use of other types of
tubing will void manufacturer's warranty.
Do not open service valves or remove protective caps from
tubing ends until all the connections are made.
Bend tubing with bending tools to avoid kinks and flat spots.
Keep the tubing free of dirt, sand, moisture, and other
contaminants to avoid damaging the refrigerant system.
Avoid sags in the suction line to prevent the formation of oil
traps. Insulate each tube with minimum 3/8-in. (10 mm) wall
thermal pipe insulation. Inserting the tubing into the
insulation before making the connections will save time and
improve installation quality.
1. Remove service valve cover if proivded with unit.
2. Cut tubing with tubing cutter.
Remove service
connection if provided with unit.
3. Install correct size flare nut onto tubing and make
flare connection.
4. Apply a small amount of refrigerant oil to the flare
connection on the tubing.
5. Properly align tubing in with service valve.
6. Tighten flare nut and finish installation using two
wrenches as shown in Fig. 14.
A07354
Fig. 14 - Tighten Flare Nut
!
CAUTION
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Excessive torque can break flare nut depending on
installation conditions.
8
42101930000
INSTALLATION INSTRUCTIONS
R-410A Duct Free Split System: DFC4(A/H)3, DFF4(A/H)H
WIRING CONNECTION
1. Remove field wiring cover from unit by loosening
screws.
2. Remove caps on conduit panel.
3. Connect conduit to conduit panel.
4. Properly connect both power supply and control lines
to terminal block per the connection diagram for the
appropriate unit capacity and voltage. (See Fig. 16, p.
10)
5. Ground unit in accordance with NEC and local electri‐
cal codes.
6. Use lock nuts to secure conduit.
7. Attach field wiring cover.
Outdoor
CAUTION
!
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Be sure to comply with local codes while running
wire from indoor unit to outdoor unit.
Every wire must be connected firmly. Loose wiring
may cause terminal to overheat or result in unit
malfunction. A fire hazard may also exist.
Therefore, be sure all wiring is tightly connected.
No wire should be allowed to touch refrigerant
tubing, compressor or any moving parts.
Disconnecting means must be provided and shall
be located within sight and readily accessible from
the air conditioner.
Connecting cable with conduit shall be routed
through hole in the conduit panel.
unit
Terminal Block
Ove
r 1.5
7" (
40m
m)
Conduit panel
G
Conduit
A07455
Fig. 15 - Field Wiring
ELECTRICAL DATA
UNIT
SIZE
09
12
18
24
OPERATING
VOLTAGE
COMPRESSOR
MAX/MIN
VOLTS-PH-HZ
127/104
115-1-60
253/187
208/230-1-60
42101930000
OUTDOOR FAN
RLA
LRA
7.5
40
9.9
47
7.3
9.7
MCA
MAX
FUSE/CB
AMP
INDOOR FAN
FLA
HP
W
VOLTS
0.69
0.102
23
35 DC
32.6
0.78
0.224
53
34.8
0.62
0.218
100
208/230-1-60
FLA
HP
W
1.1
0.034
20
12
20
1.18
0.044
25
15
25
0.26
0.075
31
11
20
0.39
0.112
50
14
25
9
INSTALLATION INSTRUCTIONS
R-410A Duct Free Split System: DFC4(A/H)3, DFF4(A/H)H
CONNECTION DIAGRAMS
CONNECTING CABLE
CONNECTING CABLE
CONNECTING CABLE
A07654
Fig. 16 - Connection Diagrams
10
42101930000
INSTALLATION INSTRUCTIONS
R-410A Duct Free Split System: DFC4(A/H)3, DFF4(A/H)H
CAUTION
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Refrigerant tubes and indoor coil should be evacuated using
the recommended deep vacuum method of 500 microns.
The alternate triple evacuation method may be used if the
procedure outlined below is followed. Always break a
vacuum with dry nitrogen.
Never use the system compressor as a vacuum pump.
SYSTEM VACUUM AND CHARGE
A
Low Side
B
High Side
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
LEAK IN
SYSTEM
VACUUM TIGHT
TOO WET
TIGHT
DRY SYSTEM
0
1
2
3 4
5
MINUTES
6
7
Indoor Unit
Refrigerant
Outdoor Unit
Deep Vacuum Method
The deep vacuum method requires a vacuum pump capable
of pulling a vacuum of 500 microns and a vacuum gage
capable of accurately measuring this vacuum depth. The deep
vacuum method is the most positive way of assuring a system
is free of air and liquid water. (See Fig. 19)
MICRONS
Using Vacuum Pump
1. Completely tighten flare nuts A, B, C, D, connect
manifold gage charge hose to a charge port of the low
side service valve.
2. Connect charge hose to vacuum pump.
3. Fully open the low side of manifold gage.
4. Start vacuum pump
5. Evacuate using either deep vacuum or triple evacu‐
ation method.
6. After evacuation is complete, fully close the low side
of manifold gage and stop operation of vacuum
pump.
7. The factory charge contained in the outdoor unit is
good for up to 25 ft. (8 m) of line length.
8. Disconnect charge hose from charge connection of
the low side service valve.
9. Fully open service valves B and A.
10. Securely tighten caps of service valves.
C
A95424
Fig. 19 - Deep Vacuum Graph
D
Service Valve
A07360
Fig. 17 - Service Valve
Manifold Gage
500 microns
Low side valve
Charge hose
High side valve
Charge hose
Vacuum pump
Low side valve
Triple Evacuation Method
The triple evacuation method should only be used when
vacuum pump is only capable of pumping down to 28 in. of
mercury vacuum and system does not contain any liquid
water. Refer to Fig. 20 and proceed as follows:
1. Pump system down to 28 in. of mercury and allow
pump to continue operating for an additional 15
minutes.
2. Close service valves and shut off vacuum pump.
3. Connect a nitrogen cylinder and regulator to system
and open until system pressure is 2 psig.
4. Close service valve and allow system to stand for 1
hr. During this time, dry nitrogen will be able to diffuse
throughout the system absorbing moisture.
5. Repeat this procedure as indicated in Fig. 20. System
will then be free of any contaminants and water
vapor.
A07361
Fig. 18 - Manifold
42101930000
(see next page)
11
INSTALLATION INSTRUCTIONS
R-410A Duct Free Split System: DFC4(A/H)3, DFF4(A/H)H
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
Final Tubing Check
IMPORTANT: Check to be certain factory tubing on both
indoor and outdoor unit has not shifted during shipment.
Ensure tubes are not rubbing against each other or any
sheet metal. Pay close attention to feeder tubes, making
sure wire ties on feeder tubes are secure and tight.
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
RELEASE CHARGE INTO SYSTEM
Fig. 20 - Triple Evacuation Method
START-UP
Test Operation
Perform test operation after completing gas leak and
electrical safety check.
SYSTEM CHECKS
1. Conceal the tubing where possible.
2. Make sure that the drain tube slopes downward along
its entire length.
3. Ensure all tubing and connections are properly insu‐
lated.
4. Fasten tubes to the outside wall, when possible.
5. Seal the hole through which the cables and tubing
pass.
INDOOR UNIT
AUTO/COOL
Manual Button
A07363
1. Push the “ON/OFF” button on Remote Control to be‐
gin testing.
NOTE: A protection feature prevents air conditioner from
being activated for approximately 3 minutes.
2. Push MODE button, select COOLING, HEATING,
FAN mode to check if all functions work correctly.
3. When ambient temperature is lower than 63F/17C,
the unit cannot be controlled by Remote Control to
run in cooling mode. For this condition, manual opera‐
tion must be used.
(1.) Open front panel of the indoor unit;
(2.) Push the manual switch once to energize the unit.
4. Be sure to set manual switch to “OFF” (by pushing it
twice) after finishing test operation.
NOTE: For Heat Pumps, follow the same procedure.
12
1.
2.
3.
4.
Do all Remote Control buttons function properly?
Do the display panel lights work properly?
Does the air deflection louver function properly?
Does the drain work?
OUTDOOR UNIT
1. Are there unusual noises or vibrations during opera‐
tion?
Explain Following Items To Customer With The Aid Of
The Owner's Manual:
1. How to turn air conditioner on and off; selecting
COOLING, HEATING and other operating modes;
setting a desired temperature; setting the timer to au‐
tomatically start and stop air conditioner operation;
and all other features of the Remote Control and dis‐
play panel.
2. How to remove and clean the air filter.
3. How to set air deflection louver.
4. Explain care and maintenance.
5. Present the Owner's Manual and installation instruc‐
tions to customer.
42101930000
INSTALLATION INSTRUCTIONS
R-410A Duct Free Split System: DFC4(A/H)3, DFF4(A/H)H
TROUBLESHOOTING
GENERAL SYSTEM GUIDE
Cooling
Operation
Lamp
X
On
Timer
Lamp
X
On
Failure Mode
Indoor fan speed has been out of control for over 1 minute
Indoor room temp. or evaporator sensor is open circuit or short circuited
Compressor over-current protection has been activated four times
EEROM error
Indoor unit communication error
(Illuminates simultaneously)
Heat
Operation
Lamp
X
X
X
X
X
= Flashing
Timer
Lamp
X
X
X
X
Defrosting
Lamp
X
X
X
X
Auto
Lamp
X
X
X
Failure Mode
Over-current protection of the compressor occurs four times
Indoor room temp. sensor is open circuit or short circuited
Temp. sensor on indoor evaporator is open circuit or short circuited
Temp. sensor on outdoor condenser is open circuit or short circuited (not cooling only modes)
Outdoor unit protects (outdoor temp. sensor, phase order, etc.)
EEROM error
Indoor unit communication error
X = Off
For additional diagnostic information, refer to the Service Manual.
OPERATION AUTO
TIMER
ECON PRE-DEF.
TIMER OPERATION
PRE.-DEF.
A07365
Model size 09
AUTO
TIMER
PRE.-DEF.
A07367
A07366
Model size 12
OPERATION
Model size 18-24
Fig. 21 - LED Display Panel
42101930000
International Comfort Products, LLC
Lewisburg, TN 37091
13